Reusable  Packaging Assembly

ABSTRACT

A packaging assembly includes a top section, a bottom section releasably connected by at least one fastener. The top section includes a top body defining a label opening and a transparent label cover closing the label opening. The top section is configured to removably retain a shipping label under the transparent label cover. The bottom section includes a bottom body, at least a first package recess being defined in the bottom section that removably accommodates at least a first internal package therein. The first package recess has a first recess width approximately equal to a first package width. A user releases the fastener to open the top and bottom sections and remove the internal package. The shipping label is removed, manipulated to display a return address and reinserted under the label cover so the packaging assembly can be returned.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser. No. 62/830,793, filed on Apr. 8, 2019, the contents of which are herein incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to packaging, and more particularly, to packaging assemblies designed for repeated use.

BACKGROUND OF THE INVENTION

With the rapid growth of e-commerce, consumers are able to order virtually anything they desire off the Internet and have it delivered right to their homes or businesses. Many consumers will even have consumable items shipped to them automatically on a recurring basis. While these online purchases offer various economies relative to traditional brick and mortar purchases, one area in which they often create greater waste is in the use of the packaging materials necessary to ensure that the products survive the vicissitudes of shipping and handling.

To some extent, consumers can take the initiative to recycle and/or use some of the packaging materials, but a very significant portion stills goes directly to landfills. Some merchants try to help by offering the option for the consumers to return packaging materials for recycling, but this often entails demands on the consumers' time (e.g., going online to obtain and print shipping labels, re-taping the packaging and affixing the label). As a result, many consumers simply throw away the packaging, anyway.

As experienced during the COVID-19 pandemic, home delivery is the only option available to many consumers to receive products—particularly any consumable products not offered by brick and mortar retailers deemed essential. While the limited travel associated with this pandemic has been observed to afford other environmental benefits. It can be expected that a reduction in packaging waste entering landfills will not be one of them.

SUMMARY OF THE INVENTION

In view of the foregoing, it is an object of the present invention to provide an improved packaging assembling that can be more easily returned and reused. According to an embodiment of the present invention, a packaging assembly includes a top section, a bottom section releasably connected by at least one fastener. The top section includes a top body defining a label opening and a transparent label cover closing the label opening. The top section is configured to removably retain a shipping label under the transparent label cover. The bottom section includes a bottom body, at least a first package recess being defined in the bottom section that removably accommodates at least a first internal package therein. The first package recess has a first recess width approximately equal to a first package width.

According to a method aspect, a method of using the packaging assembly include receiving the packaging assembly, releasing the fastener of the packaging assembly, opening the top and bottom sections of the unfastened packaging assembly, removing the at least one internal package from the at least one recess, removing the shipping label from under the transparent label cover, manipulating and reinserting the shipping label under the transparent label cover so that a return address is shown through the transparent label cover, closing the top and bottom sections, re-securing the fastener to re-fasten the closed top and bottom sections, and sending the packaging assembly to the return address.

These and other objects, aspects and advantages of the present invention will be better appreciated in view of the drawings and following detailed description of preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an upper perspective view of a packaging assembly including a top section and a bottom section in a closed configuration, according to an embodiment of the present invention;

FIG. 2 is a lower perspective view of the packaging assembly of FIG. 1;

FIG. 3 is a perspective view of the packaging assembly of FIG. 1 with the top and bottom sections in an open configuration;

FIG. 4 is an exploded upper perspective view of the top section of FIG. 1;

FIG. 5 is an exploded upper perspective view of the bottom section of FIG. 1;

FIG. 6 is a lower perspective view of a bottom section interior liner of the bottom section of FIG. 1;

FIG. 7 is a cross-sectional view of the packaging assembly taken along line 7-7 of FIG. 1;

FIG. 8 is an upper perspective view of the packaging assembly of FIG. 1 in the open configuration, with internal packages stored therein;

FIG. 9 is an upper perspective of a packaging assembly including a top section and a bottom section in a closed configuration, according to another embodiment of the present invention;

FIG. 10 is an upper perspective view of the packaging assembly of FIG. 9 with the top and bottom sections in the open configuration

FIG. 11 is an upper perspective of a packaging assembly including a top section and a bottom section in a closed configuration, according to a further embodiment of the present invention;

FIG. 12 is a bottom view of the packaging assembly of FIG. 11; and

FIG. 13 is an upper perspective view of the packaging assembly of FIG. 9 with the top and bottom sections in the open configuration.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1-3, according to an embodiment of the present invention, a packaging assembly 10 includes a top section 12 and a bottom section 14 which cooperatively define an enclosed interior therebetween when in a closed configuration (FIGS. 1 and 2). The top and bottom sections 12, 14 are releasably connected by at least one fastener 16, such that release of the connection therebetween allows the sections 12, 14 to be moved into an open configuration (FIG. 3). Advantageously, the top and bottom sections 12, 14 are connected by one or more hinges 20 located on a side opposite the fastener 16, such that the sections 12, 14 are pivotable between the closed and open configurations.

Referring also to FIG. 4, the top section 12 includes a top body 22 with exterior edges protected by a top bumper 24. A top liner 26 covers an inner surface of the top body 22. A label opening 30 is defined in the top body 22 which is closed by a transparent label cover 32. Hinge top portions 34 of the hinges 20 are also located on the top body 22, as is a catch 36 of the fastener 16.

The top body 22 is preferably made from a rigid and durable material. Aluminum is preferred for its favorable combination of strength and weight properties. The hinge top portions 34 can be formed integrally with the top body 22 or formed separately and connected thereto. Decorative symbols, text, or the like can be etched or otherwise formed on visible portions of the top body 22.

The top bumper 24 is preferably formed of an elastic material, such as a rubber, with shock-absorbing properties. The bumper 24 covers and extends outward of the edges of the top body 22, cushioning drop-related impacts from any angle. The resultant recessed position of exposed areas of the top body 22 also offers protection from scratches and abrasions from other objects. The bumper 24 is preferably affixed to the top body 22 via plurality of screws 40, or the like. Other means of fastening could be employed, but a releasable fastener is preferred to allow replacement of the top bumper 24, as necessitated by wear or damage, or otherwise desired.

The top liner 26 is preferably contoured and dimensioned to closely fit the entire inner surface of the top body 22. Like the top bumper 24, the top liner 26 is also preferably formed of an elastic material, such as a rubber. A label recess 42 is defined in an upper surface of the top liner 26 underlying the label opening 30 and the label cover 32. A label insertion slot 44 is defined along one side of the label opening 30 and a label retention notch 46 is formed extending downwardly from the top liner 26 opposite the label insertion slot. The use of the label recess, slot and notch 42-46 in conjunction with the label opening and cover 30, 32 will be described in greater detail below.

Referring also to FIG. 5, the bottom section 14 includes a bottom body 50 with exterior edges protected by a bottom bumper 52. A bottom liner 54 covers an inner surface of the bottom body 50. Hinge bottom portions 56 are located on the bottom body 50, as is a clasp assembly 60 of the fastener 16.

The bottom body 50 is preferably made from the same rigid and durable material as the top body 22 (e.g., aluminum), with the hinge bottom portions 56 formed therewith or connected thereto. Decorative symbols, text, or the like can be etched or otherwise formed on visible portions of the bottom body 50. The bottom body 50 further includes interior ribs 62 which support the bottom liner 54. Aligned notches 64 are defined in the ribs 62. A vertically extending slot 66 is defined at each corner of the bottom body 50 to engage the bottom bumper 52.

The bottom bumper 52 is preferably formed of the same elastic material as the top bumper 24, and likewise covers and extends outward of the edges of the bottom body 50, cushioning drop-related impacts from any angle and similarly recesses and offers protection to exposed areas of the bottom body 50. Like the top bumper 24, the bottom bumper is preferably affixed to the bottom body 50 via a plurality of screws 40, or other releasable fastener.

In the depicted embodiment, the depth of the bottom body 50 is greater than that of the top body 22. Consequently, vertically extending legs 70 of the bottom bumper 52 are longer than corresponding legs 72 of the top bumper 24. As the legs 70 are intentionally formed of a flexible material, the additional length can result in a tendency to pull away from the bottom body 50 unless secured thereto. To this end, vertically extending protrusions 74 are formed on inner surfaces of each of the legs 70 which are engaged in the slots 66.

Referring also to FIG. 6, the bottom liner 54 is, like the bumpers 24, 53 and the top liner 26, is preferably formed of an elastic material. The bottom liner 54 has an upper surface 76, with a plurality of package recesses 80, 82 formed extending downwardly therefrom. The ribs support the upper surface 76. First recesses 80 have a greater depth and extend down to the inner surface of the bottom body 50, while second recesses 82 have a shallowed depth and are supported within the notches 64 of the ribs 62.

A periphery 84 of the upper surface 76 extends between opposing peripheries 86, 90 of the top and bottom bodies 22, 50. With the top and bottom sections 12, 14 in the closed configuration, the periphery 84 is slightly compressed between the top and bottom bodies 22, 50 to ensure a peripheral seal, helping to prevent moisture, dust, etc. Upper and lower protrusions 92, 94 from the periphery 84 engage inside the top and bottom bodies 22, 50, respectively, to ensure proper alignment of the periphery 84. In general, the elasticity of the periphery 84 and protrusions 92, 94 allows some flexing between the top and bottom sections 12, 14 in response to impact, minimizing the likelihood of fracturing or other permanent damage.

Referring also to FIG. 7, the fastener 16 includes the catch 36 formed on the top body 22 and the clasp assembly 60 connected to the bottom body 50. The clasp assembly 60 includes a latch arm 96, which releasably engages the catch 36, and a pivot arm 100, which hingedly connects the latch arm 96 to the bottom body 50. The catch 36 and clasp assembly 60 are located in respective recesses 102, 104 of the top and bottom bodies 22, 50 so that the fastener 16 does not extend appreciably beyond the outer sides thereof when engaged.

With continued reference to FIG. 7, the label opening 30 and transparent cover 32 allow a label 106 (shown in heavy broken lines in FIG. 7) to be easily seen from outside the package assembly 10. The label 106 includes a first portion 110 foldably connected to a second portion 112 at an apex 114. The first portion 110 is inserted through the label insertion slot 44 into the label recess 42 below the cover 30. The second portion 112 extends from the apex 114 to a distal end that is secured in the label notch 46. With the top and bottom sections 12, 14 in the open configuration, the label 106 can be easily removed by pulling the apex 114 away from the insertion slot 44.

To help ensure a tight seal between the top body 22 and the label cover 32 around the label opening 30, the label cover includes a reduced height peripheral lip 116 which seats in a perimetric recess 120 around an inner side of the opening 30. The top liner 26 engages around the entire interface between the lip 116 and recess 120, helping to ensure the seal. Additionally, the cover 32 could be glued or otherwise secured into the opening 30; although a securement which permits relatively easy replacement of the cover 32 is preferred.

Referring particularly to FIG. 3, each of the first package recesses 80 has substantially identical dimensions, including a width 122 and a length 124. Likewise, each of the second package recesses 82 has substantially identical dimensions, including a width 126 and a length 130. Referring now to FIG. 8, internal packages 132A-D, 134 are supplied for the package assembly 10. Each of the internal packages 132A-D has a width slightly greater than the width 122 to ensure a slight interference fit within a respective first package recess 80. Likewise, each of the internal packages 134 has a width slightly greater than the width 126 to ensure a slight interference fit within a respective second package recess 82. The use of the “approximately equal” herein with respect to internal package and recess dimensions encompasses this relationship, as well as other dimensions close enough to each other that the internal packages will not move within the recesses absent the application of some external force other than gravity.

The secure fit is enhanced by the flexible nature of the bottom liner 54, preventing movement of the internal packages 132A-D, 134 during shipping and handling. Thicknesses of the packages 132A-D, 134 are selected to ensure they can be accommodated within the top liner 26 with the top and bottom sections 12, 14 in the closed configuration. If desired, the thicknesses can be selected to ensure slight engagement with the top liner 26 in the closed configuration. Preferably, the relative depths of the recesses 80, 82 and the relative thicknesses of the packages 132A-D, 134 are such that, with the packages fully inserted into respective recesses, the upward facing sides of each of the packages 132A-D, 134 are coplanar.

Lengths of the internal packages 132A-D, 134 are selected to be less than or approximately equal to the length 124, 130 of the respective first or second package recesses 80, 82. Advantageously, some packages shorter than the full length 124, 130 can have lengths selected to allow multiple packages to be stored in a given recess. For example, the lengths of the internal packages 132C, D allow one of each to be stored end-to-end within the same first package recess 80. Likewise, two of the internal packages 134 could be stored end-to-end within the same second package recess 82.

It will be appreciated that some or all the features of the present invention could be readily applied to package assemblies having different overall and/or relative dimensions than the package assembly 10. For instance, referring to FIGS. 9 and 10, a smaller package assembly 10′ embodying the same features as described above. In the description of alternate embodiments, like features are labeled with like reference numbers followed by one or more prime notations. In the package assembly 10′, the package recesses 80′, 82′ are preferably identical in dimensions to the recesses 80, 82, such that the same internal packages 132A-D, 134 could be used with either package assembly.

In use, a plurality of assembled package assemblies 10, 10′ are located at a fulfillment center or the like along with a plurality product stored in internal packages 132A-D, 134. A consumer places a one-time or recurring order, typically via the Internet, for products. Depending on the number and size of products ordered, a package assembly 10/10′ is selected to fit the associated internal packages 132A-D, 134. The internal packages 132A-D, 134 are placed in the appropriate first and second recesses 80/80′, 82/82′.

A shipping label 106 is placed into the label opening 44/44′ with the shipping address visible through the cover 32/32′ on the first portion 110 and the second portion 112 secured in the notch 46. The top and bottom sections 12/12′, 14/14′ are placed in the closed configuration and secured with the fastener 16/16′. If a desired, a tamper evident strip 140/140′ (see FIGS. 1 and 9) can be placed across the fastener 16/16′. The product is then shipped to the consumer.

Upon receipt, the consumer releases the fastener 16/16′, opens the top and bottom sections 12/12′, 14/14′, and removes the internal packages 132A-D, 134. If applicable, the consumer can place empty internal packages 132A-D, 134 back into the recesses 80/80′, 82/82′. The consumer removes the shipping label 106 and reverses the fold at the apex 114 so that a return address is now visible. The re-folded label 106 is then reinserted into the opening 44/44′ so that the return address can be seen through the cover 32/32′. The top and bottom sections 12/12′, 14/14′ are returned to the closed configuration and secured with the fastener 16/16′. The package assembly 10/10′ is then returned.

Once returned, the package assembly 10/10′ is inspected. The label 106 and any returned internal packages 132A-D, 134 (which could also be reused) are removed. Any cleaning and/or replacement of components is performed, as necessary or desired. The package assembly 10/10′ is then placed back in service for reuse.

It will be appreciated that a package assembly according to the present invention offers several advantages. For example, it is likely to be completely re-usable many times, with its lifetime further extended by the ability to replace components most subject to wear. The combination of dimensionally coordinated package recesses and packages allows great flexibility with respect to the number and size of packages shipped. Additionally, the replaceability of liners allows further flexibility by permitting future re-design and reconfiguration. Also, the actual process of returning the package assembly is made largely effortless for the consumer.

Referring to FIGS. 11-13, according to a further embodiment of the present invention, a packaging assembly 10″—like the packaging assemblies 10, 10′—includes a top section 12″ and a bottom section 14″ connected by a releasable fastener 16″ and pivotable between open and closed configurations via hinges 20″. Also, package recesses 80″, 82″ in the top and bottom sections 12″, 14″ are dimensioned to closely accommodate desired combinations of internal packages 132A-D, 134.

Likewise, a shipping label 106″ is visible through a transparent label cover 32″, which closes a label opening 30″ defined in the top section 12″, and can easily be removed and reinserted for returning the packaging assembly 10″ for reuse. The depicted packaging assembly 10″ is similar in size to the packaging assembly 10″, but it will be appreciated that it could readily be made in other sizes (e.g., a size similar to the packaging assembly 10). However, certain modifications relative to the packaging assemblies 10, 10′ allow the packaging assembly 10″ to facilitate manufacturing.

For example, the top and bottom bodies 22″, 50″ are each integrally molded from a rigid plastic material. No separate bumpers or liners are affixed thereto. Molded protrusions 140″ are located on the molded top body 22″, and a molded lower rim 142″ of the lower body 50″ has protruding corners 144″, which afford a stand-off from adjacent surfaces.

Rather than the label 106″ being retained between a top liner and the label cover 32″, a lower perimeter 146″ of the label opening extends under a perimeter of the label cover 32″. Edges of the label 106″ are retained in a space between the lower perimeter 146″ and the label cover 32″. The label 106″ can be folded as described in connection with the label 106, but both portions of the folded label would be retained above the lower perimeter 146″.

Rather than being formed in a separate bottom liner, the first and second recesses 80″, 82″ are integrally molded into the bottom body 50″. A spacing between the recesses 80″, 82″ is also reduced relative to the packaging assemblies 10, 10′, and shared middle wall 150″ between first recesses 80″ extends upwardly for only a portion of the total depth of the recesses 80″.

To help ensure a secure closure between the top and bottom sections 12″, 14″, the top body 22″ includes a lower molded peripheral lip 152″ and the bottom body 50″ includes a upper molded peripheral lip 154″. When the packaging assembly 10″ is closed, the upper lip 154″ sits of the bottom body 50″ sits closely inside the lower lip 152″ of the top body 22″.

Rather than utilizing a multi-part clasp assembly, the fastener 16″ has a unitary molded clasp 156″ hinged to the bottom body 50″ at the bottom of a lower clasp recess 104″. An upper clasp edge 160″ is securable over a retention edge 162″ in an upper clasp recess 102″ to retain the packaging assembly 10″ in the closed configuration. To help prevent inadvertent disengagement of the edges 160″, 162″, the clasp 156″ further includes a retention tab 164″ defining a retention opening 166″ extending inwardly of the clasp edge 160″. A molded retention button 170″ extends upwardly from the top body 22″ in an upper clasp recess 102″. The opening 166″ snaps over the button 170″. To allow disengagement of the edges 160″, 162″ the retention tab 164″ must be pulled to disengage the opening 166″ from the button 170″.

In general, the foregoing embodiments are described for illustrative and exemplary purposes; the present invention is not necessarily limited thereto. Rather, those skilled in the art will appreciate that various modifications, as well as adaptations to particular circumstances, will fall within the scope of the invention as herein shown and described and of the claims appended hereto. 

What is Claimed is:
 1. A packaging assembly comprising: a top section including a top body defining a label opening, the top section also including a transparent label cover closing the label opening, the top section being configured to removably retain a shipping label under the transparent label cover; a bottom section including a bottom body, at least a first package recess being defined in the bottom section, the first package recess removably accommodating at least a first internal package therein, the first package recess having a first recess width approximately equal to a first package width; and at least one fastener releasably connecting the top and bottom sections.
 2. The packaging assembly of claim 1, further comprising at least one hinge pivotably connecting the top and bottom sections such that, with the at least one fastener released, the top and bottom sections are pivotable between opened and closed configurations.
 3. The packaging assembly of claim 1, wherein the label opening has a lower perimeter extending under a perimeter of the transparent label cover such that edges of the shipping label are retainable in a space between the lower perimeter and the transparent label cover.
 4. The packaging assembly of claim 1, wherein the top and bottom body are both single, integrally molded plastic pieces.
 5. The packaging assembly of claim 4, wherein the top body includes a lower peripheral lip and the bottom body includes an upper peripheral lip, the lower and upper peripheral lips sitting side-by-side around a perimeter of a junction between the top and bottom sections.
 6. The packaging assembly of claim 4, wherein the first package recess is molded into the bottom body.
 7. The packaging assembly of claim 4, wherein a second package recess is molded into the bottom body adjacent to the first package recess.
 8. The packaging assembly of claim 7, wherein the first and second package recesses are identically dimensioned.
 9. The packaging assembly of claim 7, wherein a shared middle wall between the first and second package recesses extends upwardly therebetween for only a portion of a total depth of the first and second package recesses.
 10. The packaging assembly of claim 7, wherein a third package recess is molded into the bottom body adjacent to the first and second package recesses.
 11. The packaging assembly of claim 10, wherein the third package recess is shallower than the first and second package recesses.
 12. The packaging assembly of claim 1, wherein the first package recess removably accommodates a second internal package therein, a second package width being approximately equal to the first recess width.
 13. The packaging assembly of claim 12, wherein the first package recess has a first recess length that is approximately equal to a combined length of the first and second packages.
 14. The packaging assembly of claim 13, wherein upward facing surfaces of the first and second internal packages are coplanar.
 15. The packaging assembly of claim 12, further comprising a second package recess defined in the bottom section adjacent to the first package recess, the second package recess removably accommodating a second internal package therein, the second package recess having a second recess width approximately equal to a second package width.
 16. The packaging assembly of claim 15, wherein the first and second package recesses are identically dimensioned.
 17. The packaging assembly of claim 16, wherein the first package recess removably accommodates a third internal package therein, a third package width being approximately equal to the first recess width.
 18. The packaging assembly of claim 17, wherein the first package recess has a first recess length that is approximately equal to a combined length of the first and third packages.
 19. The packaging assembly of claim 18, wherein the second package recess has a second recess length that is approximately equal to a second package length.
 20. The packaging assembly of claim 15, wherein the second package recess is shallower than the first package recess.
 21. The packaging assembly of claim 20, wherein upward facing surfaces of the first and second internal packages are coplanar.
 22. The packaging assembly of claim 1, wherein the at least one fastener is located in upper and lower clasp recesses of the top and bottom bodies, respectively, so that the at least one fastener does not extend beyond outer sides thereof.
 23. The packaging assembly of claim 22, wherein the at least one fastener includes a unitary molded clasp hinged to a lower edge of the lower clasp recess and having an upper clasp edge releasably secured over an upper clasp edge in the upper clasp recess.
 24. The packaging assembly of claim 23, wherein the unitary molded clasp further includes a retention tab extending inwardly of the upper clasp edge and defining a retention opening secured over a retention button extending upwardly from the top body.
 25. A method of using a packaging assembly, the method comprising: receiving the packaging assembly; releasing a fastener of the packaging assembly; opening top and bottom sections of the unfastened packaging assembly; removing at least one internal package from at least one recess in the bottom section; removing an address label from under a transparent label cover in the top section; manipulating and reinserting the address label under the transparent label cover so that a return address is shown through the transparent label cover; closing the top and bottom sections; re-securing the fastener to re-fasten the closed top and bottom sections; and sending the packaging assembly to the return address.
 26. The method of claim 25, further comprising of inserting one or more previously used internal packages into the at least one recess before closing the top and bottom sections. 